Dual drive compressor

ABSTRACT

A dual drive compressor is disclosed including a suction chamber having at least one muffler incorporated therein, wherein the at least one muffler attenuates pulsations caused by a fluid received in the compressor.

FIELD OF THE INVENTION

The invention relates to a compressor and more particularly to a dual drive compressor including a suction chamber having at least one muffler incorporated therein.

BACKGROUND OF THE INVENTION

Hybrid electric vehicles having improved fuel economy over internal combustion engine and other vehicles are quickly becoming more popular as a cost of traditional fuel increases. Typically, the improved fuel economy is due to known technologies such as regenerative braking, electric motor assist, and engine-off operation.

Although the technologies improve fuel economy, there are drawbacks. One such drawback is that accessories powered by a fuel-powered engine no longer operate when the fuel-powered engine is not in operation. One major accessory that does not operate is an air-conditioning compressor, which cools air in a passenger compartment of the vehicle. Ultimately, without the use of the compressor, a temperature of the air in the passenger compartment increases to a point above a desired temperature and the fuel-powered engine of the vehicle must restart.

Accordingly, vehicle manufacturers have used a full electric compressor on hybrid vehicles. The full electric compressor operates whether the fuel-powered engine is operating or not. A significant disadvantage of the full electric compressor is the inefficiency that occurs from converting engine shaft power to electricity, then electricity back to compressor shaft power. Thus, the use of a hybrid compressor which is mechanically and electrically driven is advantageous.

One such hybrid compressor is a dual drive scroll compressor described in U.S. Pat. No. 6,543,243 entitled HYBRID COMPRESSOR, hereby incorporated herein by reference in its entirety. The compressor includes a pair of scroll assemblies which operate independently of each other. One of the scroll assemblies is mechanically driven by a pulley system in mechanical communication with a fuel-powered engine of the vehicle. The other of the scroll assemblies is electrically driven and can be used when the fuel-powered engine is off, or when an excess of battery power is present. Therefore, it is possible to operate the compressor at maximum efficiency without impacting the temperature of the passenger compartment of the vehicle. However, during operation of the compressor, a noise generated thereby is perceptible by passengers of the vehicle. Operating noise is primarily caused by pressure pulsations associated with compression. In practice, different structures are used for reducing the pressure pulsations, such as chambers where pressure waves are attenuated by expansion.

U.S. Patent Application Publication No. 2005/0002800 entitled DEVICE HAVING A PULSATION REDUCING STRUCTURE, A PASSAGE FORMING BODY AND COMPRESSOR, hereby incorporated herein by reference in its entirety, discloses a compressor having a suction chamber which functions as a muffler. The suction chamber cooperates with a plurality of restricting passages to reduce pulsations of a suction gas.

Although the aforementioned compressors operate efficiently, the compressors are difficult to package in an existing single compressor envelope and involve high manufacturing costs.

Accordingly, it would be desirable to produce a dual drive compressor wherein a cost, complexity, and size thereof are minimized and an effectiveness thereof is maximized.

SUMMARY OF THE INVENTION

In concordance and agreement with the present invention, a dual drive compressor wherein a cost, complexity, and size thereof are minimized and an effectiveness thereof is maximized, has surprisingly been discovered.

In one embodiment, the hybrid compressor comprises a housing assembly having a discharge chamber and a suction chamber formed thereon, the suction chamber having at least one muffler incorporated therein; a first compression assembly having a plurality of compression chambers disposed in the housing assembly, the compression chambers in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet; and a second compression assembly having a plurality of compression chambers disposed in the housing assembly, the compression chambers in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet.

In another embodiment, the dual drive compressor comprises a housing assembly having a discharge chamber and a suction chamber formed thereon, the discharge chamber formed on one of an upper portion and a side portion of the housing assembly, and the suction chamber formed on one of the upper portion and the side portion of the housing assembly, wherein the suction chamber includes at least one muffler incorporated therein; a first compression assembly having a plurality of compression chambers disposed in the housing assembly, the compression chambers in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet; a second compression assembly having a plurality of compression chambers disposed in the housing assembly, the compression chambers in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet, wherein the second compression assembly and the first compression assembly operate independently; and at least one fluid separator disposed in the housing assembly, wherein the at least one fluid separator is adapted to separate a liquid from a fluid.

In another embodiment, the dual drive compressor for a refrigeration system comprises a housing assembly having a discharge chamber and a suction chamber formed thereon, the discharge chamber formed on one of an upper portion and a side portion of the housing assembly, and the suction chamber formed on one of the upper portion and the side portion of the housing assembly, wherein the suction chamber includes at least one muffler incorporated therein; a first compression assembly having a plurality of compression chambers disposed in the housing assembly, the first compression assembly adapted to be driven by a mechanical input, wherein the compression chambers are in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet; a second compression assembly having a plurality of compression chambers disposed in the housing assembly, the second compression assembly adapted to be driven by an electrical input, wherein the compression chambers are in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet, and wherein the second compression assembly and the first compression assembly operate independently; and at least one oil separator disposed in the housing assembly, wherein the at least one oil separator is adapted to separate an oil from a refrigerant.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects and advantages of the invention will become readily apparent to those skilled in the art from reading the following detailed description of the invention when considered in the light of the accompanying drawings, in which:

FIG. 1 is a cross-sectional view of a dual drive compressor according to an embodiment of the invention; and

FIG. 2 is a partially exploded perspective view of the dual drive compressor illustrated in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

The following detailed description and appended drawings describe and illustrate an exemplary embodiment of the present invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. It is understood that materials other than those described can be used without departing from the scope and spirit of the invention.

FIG. 1 shows a dual drive compressor 10 according to an embodiment of the invention. The compressor 10 includes a housing assembly having a first housing shell 12, a second housing shell 14, and a third housing shell 16. The first housing shell 12, the second housing shell 14, and the third housing shell 16 cooperate to form a hollow chamber therebetween. The housing shells 12, 14, 16 can be produced from any conventional material such as aluminum, for example. Although each of the housing shells 12, 14, 16 shown has a substantially circular cross-sectional shape, other cross-sectional shapes can be used as desired. The housing shells 12, 14, 16 can be joined using fasteners such as bolts, screws, clips, and the like, for example.

A first compression assembly 18 and a second compression assembly 20 are disposed in the housing assembly. Although the compression assemblies 18, 20 shown are scroll assemblies, it is understood that other compression assemblies such as swash plate, rolling piston, and rotary vein assemblies, for example, or any combination thereof, can be employed as desired. In the embodiment shown, the first compression assembly 18 includes an orbit scroll 22 and a fixed scroll 24. The second compression assembly 20 also includes an orbit scroll 26 and a fixed scroll 28.

In the embodiment shown, the orbit scroll 22 is driven by a mechanical input 30, as shown in FIG. 2, such as a pulley system in mechanical communication with an engine of a vehicle, for example. The orbit scroll 26 is driven by an electrical input 32 such as an electric motor, for example. It is understood that the orbit scrolls 22, 26 can be driven by other sources if desired. It is further understood that the orbit scrolls 22, 26 can be independently operated, whereby operation of the orbit scroll 22 does not cause or depend on operation of the orbit scroll 26. As illustrated, the orbit scroll 22 includes an end plate 34 having a spiral involute 36 extending laterally outwardly therefrom. The orbit scroll 26 also includes an end plate 38 having a spiral involute 40 extending laterally outwardly therefrom.

In the embodiment shown, the fixed scrolls 24, 28 share an end plate 42 having a pair of spiral involutes 43, 44 extending laterally outwardly therefrom in opposing directions. The spiral involute 43 is adapted to receive and engage the spiral involute 36 formed on the end plate 34 of the orbit scroll 22 to define a plurality of compression chambers 45 therebetween. The spiral involute 44 is adapted to receive and engage the spiral involute 40 formed on the end plate 30 of the orbit scroll 26 to define a plurality of compression chambers 46 therebetween. It is understood that wraps of the involutes 36, 40, 43, 44 can be located and sized, as desired.

The end plate 30 of the fixed scrolls 24, 28 includes a first discharge outlet (not shown) and a second discharge outlet 47 formed therein. The first discharge outlet is in fluid communication with the compression chambers 45 and a discharge chamber 48 through a first discharge path (not shown). The second discharge outlet 47 is in fluid communication with the compression chambers 46 and the discharge chamber 48 through a second discharge path 49. The first discharge path and the second discharge path 49 facilitate a flow of a fluid (not shown) such as an oil-refrigerant mixture, for example, from the compression chambers 45, 46 to the discharge chamber 48.

In the embodiment shown, the discharge chamber 48 is formed on an upper portion of the second housing shell 14 between the first compression assembly 18 and the second compression assembly 20. It is understood that the discharge chamber 48 can be formed elsewhere on the compressor 10 as desired. It is also understood that the discharge chamber 48 can have any shape and size as desired. In the embodiment shown, the discharge chamber 48 is in fluid communication with a refrigeration system (not shown) through a discharge port (not shown). It is understood that the refrigeration system can be any conventional refrigeration system such as a heating, ventilating, and air conditioning system of a vehicle, for example.

The housing assembly also includes a suction chamber 50 formed therein as shown in FIG. 2. In the embodiment shown, the suction chamber 50 is formed on a side portion of the second housing shell 14 between the first compression assembly 18 and the second compression assembly 20. It is understood that the suction chamber 50 can be formed elsewhere in the compressor 10 as desired. It is also understood that the suction chamber 50 can have any shape and size as desired. The suction chamber 50 fluidly connects a suction inlet 51 formed in the housing assembly adapted to facilitate a flow of the fluid into the compression chambers 45 of the first compression assembly 18 and a suction inlet 52 formed in the housing assembly adapted to facilitate a flow of the fluid into the compression chambers 46 of the second compression assembly 20.

In the embodiment shown, the suction chamber 50 is formed as a protuberant portion 53 extending outwardly from the second housing shell 14. The protuberant portion 53 is generally rectangular in shape and is adapted to receive a cover 54 thereon. A seal 60 is disposed between the protuberant portion 53 and the cover 54 to form a substantially fluid-tight seal therebetween. The cover 54 is affixed to the protuberant portion 53 by a plurality of fasteners 56 such as screws, bolts, and the like, for example. It is understood that the cover 54 can be affixed to the protuberant portion 53 by any conventional means as desired. The cover 54 includes a suction port 58 formed therein. The suction port 58 is adapted to permit a flow of fluid from the refrigeration system into the suction chamber 50.

The suction chamber 50 includes at least one muffler 62 incorporated therein. The at least one muffler 62 is adapted to attenuate pulsations caused by the fluid being received into the compressor 10 from the refrigeration system. In the embodiment shown, the at least one muffler 62 is a division of the suction inlet 51 into a plurality of passages. The passages divide the pulsations into separate, smaller pulsations, which results in a reduction of an operating noise of the compressor 10. It is understood that the at least one muffler 62 can be a division of the suction inlet 52 into a plurality of passages, a plurality of baffles formed in the suction chamber 50, and the like, for example.

The compressor 10 may include at least one fluid separator 66 for separating a liquid (not shown) from the fluid. In the embodiment shown, the fluid separator 66 is disposed in a separation chamber 68 formed in the housing assembly of the compressor 10. It is understood that the fluid separator 66 can be disposed in at least one of the discharge chamber 48 and the suction chamber 50 if desired.

In operation, when the mechanical input 30 is in operation, the orbit scroll 22 of the first compression assembly 18 is caused to revolve in a desired path, as is known in the art. The revolution of the orbit scroll 22 causes the spiral involute 36 of the orbit scroll 22 to cooperate with the spiral involute 43 of the fixed scroll 24, thereby compressing the fluid flowing therethrough. The compressed fluid is then discharged from the compression chambers 45 of the first compression assembly 18 through the first discharge outlet into the first discharge path. The compressed fluid flows through the first discharge path into the discharge chamber 48. From the discharge chamber 48, the compressed fluid flows through the fluid separator 66 and into the refrigeration system to be circulated therethrough.

Once the fluid has circulated through the refrigeration system, the fluid is caused to flow through the suction port 58 into the suction chamber 50 of the compressor 10. In the suction chamber 50, the pulsations of the fluid are attenuated by the muffler 62 before flowing through the suction inlet 51 and into the first compression assembly 18. In the embodiment shown, the fluid is caused to flow through the plurality of passages, dividing the flow of fluid and the pulsations thereof. The divided flow is then recombined before being received in the first compression assembly 18.

When the mechanical input 30 is not in operation, the orbit scroll 26 of the second compression assembly 20 is caused to revolve by the electrical input 32 in a desired path, as is known in the art. The revolution of the orbit scroll 26 causes the spiral involute 40 of the orbit scroll 26 to cooperate with the spiral involute 44 of the fixed scroll 26, thereby compressing the fluid flowing therethrough. The compressed fluid is then discharged from the compression chambers 46 of the second compression assembly 20 through the second discharge outlet 47 and into the second discharge path 49. The compressed fluid flows through the second discharge path 49 into the discharge chamber 48. From the discharge chamber 48, the compressed fluid flows through the fluid separator 66 and into the refrigeration system to be circulated therethrough.

Once the fluid has circulated through the refrigeration system, the fluid is caused to flow through the suction port 58 into the suction chamber 50 of the compressor 10. In the suction chamber 50, the pulsations of the fluid are attenuated by the muffler 62 before flowing through the suction inlet 52 and into the second compression assembly 18.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions in accordance with the scope of the appended claims. 

1. A hybrid compressor comprising: a housing assembly having a discharge chamber and a suction chamber formed thereon, the suction chamber having at least one muffler incorporated therein; a first compression assembly having a plurality of compression chambers disposed in the housing assembly, the compression chambers in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet; and a second compression assembly having a plurality of compression chambers disposed in the housing assembly, the compression chambers in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet.
 2. The compressor according to claim 1, wherein the discharge chamber is formed on one of an upper portion and a side portion of the housing assembly.
 3. The compressor according to claim 1, wherein the suction chamber is formed on one of an upper portion and a side portion of the housing assembly.
 4. The compressor according to claim 1, wherein the at least one muffler attenuates pulsations caused by a fluid received in the housing assembly.
 5. The compressor according to claim 1, wherein the at least one muffler is at least one of a division of the suction inlet in fluid communication with the compression chambers of the first compression assembly into a plurality of passages, a division of the suction inlet in fluid communication with the compression chambers of the second compression assembly into a plurality of passages, and a plurality of baffles formed in the suction chamber.
 6. The compressor according to claim 1, wherein the first compression assembly and the second compression assembly operate independently.
 7. The compressor according to claim 1, further comprising at least one fluid separator disposed in the housing assembly.
 8. The compressor according to claim 8, wherein at least one of the discharge chamber and the suction chamber includes the at least one fluid separator disposed therein.
 9. The compressor according to claim 1, wherein the first compression assembly is adapted to be driven by a mechanical input.
 10. The compressor according to claim 1, wherein the second compression assembly is adapted to be driven by an electrical input.
 11. A dual drive compressor comprising: a housing assembly having a discharge chamber and a suction chamber formed thereon, the discharge chamber formed on one of an upper portion and a side portion of the housing assembly, and the suction chamber formed on one of the upper portion and the side portion of the housing assembly, wherein the suction chamber includes at least one muffler incorporated therein; a first compression assembly having a plurality of compression chambers disposed in the housing assembly, the compression chambers in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet; a second compression assembly having a plurality of compression chambers disposed in the housing assembly, the compression chambers in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet, wherein the second compression assembly and the first compression assembly operate independently; and at least one fluid separator disposed in the housing assembly, wherein the at least one fluid separator is adapted to separate a liquid from a fluid.
 12. The compressor according to claim 11, wherein the at least one muffler attenuates pulsations caused by the fluid received in the housing assembly.
 13. The compressor according to claim 11, wherein the at least one muffler is at least one of a division of the suction inlet in fluid communication with the compression chambers of the first compression assembly into a plurality of passages, a division of the suction inlet in fluid communication with the compression chambers of the second compression assembly into a plurality of passages, and a plurality of baffles formed in the suction chamber.
 14. The compressor according to claim 11, wherein the at least one fluid separator is disposed in at least one of the discharge chamber and the suction chamber of the housing assembly.
 15. The compressor according to claim 11, wherein the first compression assembly is adapted to be driven by a mechanical input.
 16. The compressor according to claim 11, wherein the second compression assembly is adapted to be driven by an electrical input.
 17. A dual drive compressor for a refrigeration system comprising: a housing assembly having a discharge chamber and a suction chamber formed thereon, the discharge chamber formed on one of an upper portion and a side portion of the housing assembly, and the suction chamber formed on one of the upper portion and the side portion of the housing assembly, wherein the suction chamber includes at least one muffler incorporated therein; a first compression assembly having a plurality of compression chambers disposed in the housing assembly, the first compression assembly adapted to be driven by a mechanical input, wherein the compression chambers are in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet; a second compression assembly having a plurality of compression chambers disposed in the housing assembly, the second compression assembly adapted to be driven by an electrical input, wherein the compression chambers are in fluid communication with the discharge chamber through a discharge outlet, and in fluid communication with the suction chamber through a suction inlet, and wherein the second compression assembly and the first compression assembly operate independently; and at least one oil separator disposed in the housing assembly, wherein the at least one oil separator is adapted to separate an oil from a refrigerant.
 18. The compressor according to claim 17, wherein the at least one muffler attenuates pulsations caused by the refrigerant received in the housing assembly.
 19. The compressor according to claim 17, wherein the at least one muffler is at least one of a division of the suction inlet in fluid communication with the compression chambers of the first compression assembly into a plurality of passages, a division of the suction inlet in fluid communication with the compression chambers of the second compression assembly into a plurality of passages, and a plurality of baffles formed in the suction chamber.
 20. The compressor according to claim 17, wherein the at least one oil separator is disposed in at least one of the discharge chamber and the suction chamber of the housing assembly. 